Apparatus for applying reinforcement zones to sheet material

ABSTRACT

An apparatus for applying reinforcement zones to sheet material (e.g. paper, plastic-coated paper, synthetic-resin foil, cardboard and paperboard of all types with or without coatings), comprises a die which, when the sheet is fed between the two die members, advances a strip of reinforcement material which is stiffened by transverse bowing into a position in which the strip overlies or underlies a surface of the substrate to which it is to be transferred. As the die is closed, a two-sided cutter shapes the leading edge of the strip to be fed subsequently and severs the reinforcement patch from the strip. Further dieclosing movement brings a finger to bear yieldably against the patch to hold it in place while further die closure forces a punch through the patch and the underlying substrate and/or effects bonding of the patch to the sheet. In spite of the fact that the cutter may be heated and the strip is composed of a heat-sensitive material, adhesion is prevented by distorting the strip, i.e. by forcing it through a channel of smaller width then the strip and cutting it over a length dimensioned to cause the cut portion of the strip to spring away from the heated cutter.

United States Patent [1 1 Lowe et al.

[ APPARATUS FOR APPLYING REINFORCEMENT ZONES TO SHEET MATERIAL [75] lnventors: William F. Lowe, Bridgehampton;

Harry L. Bondy, Plainview, both of NY.

[73] Assignee: E-Z Machine Corporation,

Plainview, NY.

[22] Filed: Oct. 18, I973 [21] Appl. No.: 407,623

Primary ExaminerDouglas .l. Drummond Attorney, Agent, or Firm-Karl F. Ross; Herbert Dubno Dec. 9, 1975 [57] ABSTRACT An apparatus for applying reinforcement zones to sheet material (e.g. paper, plastic-coated paper, synthetic-resin foil, cardboard and paperboard of all types with or without coatings), comprises a die which, when the sheet is fed between the two die members. advances a strip of reinforcement material which is stiffened by transverse bowing into a position in which the strip overlies or underlies a surface of the substrate to which it is to be transferred. As the die is closed, a two-sided cutter shapes the leading edge of the strip to be fed subsequently and severs the reinforcement patch from the strip. Further die-closing movement brings a finger to bear yieldably against the patch to hold it in place while further die closure forces a punch through the patch and the underlying substrate and/or effects bonding of the patch to the sheet. In spite of the fact that the cutter may be heated and the strip is composed of a heatsensitive material, adhesion is prevented by distorting the strip, i.e. by forcing it through a channel of smaller width then the strip and cutting it over a length dimensioned to cause the cut portion of the strip to spring away from the heated cutter.

10 Claims, 13 Drawing Figures US. Patent Dec. 9, 1975 Sheet 1 of6 3,925,144

US. Patent Dec. 9, 1975 Sheet 2 of6 3,925,144

a i m wt US. Patent Dec. 9, 1975 Sheet 3 of6 3,925,144

US. Patent Dec. 9, 1975 Sheet 4 of 6 FIG. 4

US. Patent Dec. 9, 1975 Sheet 5 of6 3,925,144

FIG. 5

US. Patent Dec. 9, 1975 Sheet 6 of6 3,925,144

APPARATUS FOR APPLYING REINFORCEMENT ZONES TO SHEET MATERIAL FIELD OF THE INVENTION The present invention relates to a system for applying local patches or zones of one material to a substrate of sheet material, e.g. reinforcement patches or zones to a paper or paperboard sheet, for identification, holereinforcement or other purposes.

BACKGROUND OF THE INVENTION It is common practice in the paper art to provide holes or perforations along the margin of a sheet to allow the paper to be accommodated in a ring binder or the like. It is also conventional, where the sheet is to be subjected to considerable use or stress, to provide reinforcement zones around the/or each hole and thereby increase the tearing strength of the paper in the region of the hole to prevent the paper from becoming loose in the ring binder or similar system in which it is incorporated. The reinforcement zone may extend continuously along the perforated margin of the sheet or may be provided in patches, e.g. as reinforcement rings, only in the vicinity of each hole and the application of such patches or rings has been laborious, time consuming and primarily a manual operation heretofore. In general, it has not been possible heretofore, especially with heat-scalable materials, to satisfactorily apply reinforcement patches or rings to sheet materials so that the hole is positioned centrally or uniformly therein, so that the patch or ring is not offset with respect to the hole, so that the reinforcement zone is located properly along the edge of the sheet, and so that the product is aesthetic in appearance and also economical to manufacture. These problems are especially pronounced, when attempts have been made to automate the process.

OBJECTS OF THE INVENTION It is the principal object of the present invention to provide an apparatus or device for automatically applying zones of one material, preferably available in strip form, to a sheet-material substrate whereby the aforementioned disadvantages are obviated.

Another object is to provide a die for the application of reinforcement foils to paper, synthetic resin or paperboard sheets, especially for the reinforcement of holes formed therein, wherein each reinforcement is properly centered with respect to the hole, is located properly with respect to an edge of the sheet, has an aesthetic appearance, and is able to be applied economically and at high rates.

It is another object of the invention to provide an improved method of applying reinforcement zones to sheet material whereby the aforementioned disadvantages are obviated.

SUMMARY OF THE INVENTION These objects and others which will become apparent heretoafter are attained in accordance with the present invention, with the provision of a die or mounting assembly for applying a section or patch of a strip to sheet material and which comprises a die assembly for severing the patch or section of the foil from a strip thereof fed over a surface of the substrate as the die or at least one movable die member is displaced to press the severed section against the substrate sheet and bond the section to the latter. Preferably, the cutting portion of the die has a pair of cutting edges which shape the leading edge of the strip from which the section is severed and at the same time form the trailing edge of the severed section, the latter being held upon the substrate during further displacement of the die into its bonding position by a resiliently biased finger on the movable die member. Bonding may be effected by thermal fusion, ultrasonic or any other means, e. g. by simple pressure when the surface of the sheet or the confronting face of the severed foil sections are provided with pressure-bonding adhesives.

Where thermal bonding of the strip or foil to the sheet material is effected by a heated pressure member, forming one of the cutting edges, we prefer to feed the strip through a channel of lesser width than that of the strip and to cut the strip with a cutting edge which has a length somewhat less than the length of the cut edge of the flattened section as applied to the sheet. As a re sult, the cut section springs away from the heated cutter member and does not adhere thereto.

According to another feature of the invention, the patches are preferably formed from a synthetic-resin foil which is thermally bonded to the substrate concurrently with or subsequently to the application of the severed patch to an underlying zone of the substrate surface, the synthetic-resin strip being fed from a supply roll or the like through the channel in a direction generally transverse to the direction of displacement of the movable die member or members. The channel accommodating the strip may, as noted previously, have a width which is less than the selected width of the strip so that the latter is crowned in cross-section to provide increased stiffness and thus greater security of advance of the strip.

According to another feature of the invention, the movable die member is provided with a punch which is actuated upon further advance of a portion of this die member after the latter has applied the patch to the substrate, to form a ring binder hole or the like through the patch and the substrate. The strip may be advanced with a feed wheel having a resilient periphery, preferably formed by an O-ring, driven by a rack and pinion arrangement by way of an unirotational clutch.

DESCRIPTION OF THE DRAWING The above and other objects, features and advantages of the present invention will become more readily apparent from the following description, reference being made to the accompanying drawing in which:

FIG. 1 is a fragmentary plan view of a machine embodying the present invention;

FIG. 2 is a plan view of a portion of a die according to the invention, drawn to a larger scale than that of FIG. 1;

FIG. 3 is a cross-sectional view taken along the line Ill III of FIG. 2;

FIG. 4 is a bottom view of the other portion of the die mating with that of FIG. I;

FIG. 5 is a rear-elevational view of the die;

FIGS. 6A 6D are top views of the patch-applying region showing successive steps in the operation of the die according to the invention; and

FIGS. 7A 71) are front-elevational views, partly broken away, corresponding to FIGS. 6A 6D.

SPECIFIC DESCRIPTION In FIG. I of the drawing, we show a machine for providing reinforced ring binder holes upon a sheet S of paper, synthetic resin, metal foil, paperboard, cardboard or any other substrate which is fed by a belt 10, diagrammatically illustrated in the drawing, in the direction of an arrow 11 until the leading edge 12 of the sheet engages a stop 13 which may be interposed in its path by any control means (e.g. de-energization of an electromagnet or solenoid or by a pneumatic cylinder). A sheet S passes below a hold-down device formed by a bear 14 provided with bores 15 each of which receives a metal ball 16 or a ball of another substance depending upon the pressure to be exerted upon the sheet. The belt 10 may be continuously operated. A pair of reinforcement and punching dies 17 and 18 may be adjustably positioned on the machine frame 19 to apply reinforcement patches and perforate them as will be described in greater detail hereinafter. Once the reinforcement patch is applied and is punched through, the stop 13 is lifted to permit the sheet to continue along its path. Any conventional press arrangement (e.g. a pneumatic cylinder) may be used for closing the dies. Furthermore, the dies may be heated when the reinforcement patches are composed of a Mylar or other thermally bondable synthetic-resin material (polyester) so that thermal bonding of the patch to the substrate is effected.

As best seen in FIGS. 2 5, each of the dies (collectively shown at 20) comprises a lower die member 21 and an upper die member 22. The lower die member 21 is formed with a channel 23 having a width which is less than the width of the undeflected strip so that, as illustrated in FIGS. 7A 7D, the reinforcement strip is fed in a transversely bent state through the channel. The lower die member 21 is also formed with a pair of guide sleeves 24 and 25, accommodating respective guide rods 26 and 27 of the upper die member 22 and permitting relative vertical movement of the two parts. Because the stirp is cut by a crowned upper die member whose radius of curvative may be less than the crown on the strip, the severed section is cut progressively inwardly from its edges and springs away from the heated upper die member. Sticking of the severed section to the heated die members is thereby precluded.

A recess 28 at the rear end of the lower die member is defined between a pair of walls 29, 30 in which a shaft 31 is journaled, this shaft carrying a feed wheel 32 having a central groove in which an O-ring 33 of rubber or some other elastic material is received.

A pinion 34 is connected by a unidirectional clutch 35 to the shaft 31 so that the latter is rotated only when the pinion is driven in the counterclockwise sense (FIG. 3) by a rack 36 carried by the upper die member 22.

Directly above the wheel 32, there is provided a counter roller 40 joumaled in a pair of trunions 41 and 42 and against which the foil strip is pressed by the feed wheel 32.

At its left-hand extremity (FIG. 2) the feed channel 23 terminates in an arcuate cutting edge 43 which has the configuration of the end 44 of the patch to be applied to the substrate S (see FIGS. 6A 6D). This edge is spaced by a gap 44 from a platform 45 adapted to accommodate the sheet when the latter is inserted be tween the two halves of the die. The platform 45 is formed with a bore 46 accommodating a punch 47 of 4 the upper die half 22. The platform 45 is also provided with a sharp cutting edge 48 which cooperates with a movable die member as will be apparent hereinafter. A finger 49 is cantilevered over the platform and serves to hold down the substrate as the upper die member is lifted out of engagement therewith.

The upper die member 22 is provided with a slot 50 adapted to receive the finger 49 with clearance (FIG. 4) and with a surface 51 overlying the platform 45 and adapted to be heated by means not shown when the synthetic-resin patch is to be thermally bonded to the substrate. The punch 47 carried by the upper die member 22 is guided in a bore 52 registering with the bore 46, the punch being anchored at its upper end to a plate 53 biased upwardly by springs 54 so as to perform lost motion with respect to the remainder of the upper die member 22.

The rack 36 is vertically shiftable in a guide 55 and is urged downwardly by a spring 56 seated against a pin 57 and bracing against the lower part of a sleeve 55. A further pin 58 limits the relative displacement of the sleeve and the rack.

The upper die member is provided with a blade 60 whose cutting edges 61 and 62 correspond respectively to the cutting edges 43 and 48 described previously. In addition, the upper die member 22 is formed with a spring-biased retaining pin hold-down element or fin-. ger 63 which is urged downwardly by a spring 64.

The operation of the device will best be understood by considering FIGS. 2 5 in conjunction with FIGS. 6A 6D and FIGS 7A 7D. Assuming that a substrate S is in place between the platform 45 and the juxtaposed face 51 of the die, the upper die member 22 is lowered so that its rack 36 rotates the pinion 34 and drives the wheel 32 in the clockwise sense as viewed in FIG. 3. As a result, the foil is advanced between the wheel 32 and the counte r-roller 40 through the channel 23 over the substrate as seen in FIGS'. 6A and 7A, the direction of advance of the strip being represented by the arrow A. The leading edge 44 of the strip (FIG. 6A) has previously received a rounded contour as will be apparent hereinafter. When the desired length L of strip has been advanced over the substrate S, the rack 36 bottoms on the floor 65 of the recess 28 and the parts are in their relative position illustrated in FIG. 3.

Further advance of the upper die member 22 in the downward direction compresses the spring 56 and severs the strip S along the cutting edges 43, 48 and 61, 62 to cut a reinforcement patch P from the strip and simultaneously provide a rounded leading edge 44 upon the continuous length of strip emerging from the channel 23. The finger 63 thereupon bears against the path P to prevent it from moving while the surface 51 is further advanced to press the patch against the substrate and thermally bonded in place if a heated die and a thermally bondable strip are used. With the substrate under full compression, the upper die member 22 is no longer able to move downwardly and the press pressure applied at T (FIG. 3) drives the upper plate 53 downwardly to carry the punch 47 in this direction and form a hole H through the patch P and the underlying substrate.

With relaxation of the press pressure, the springs 54 urge the plate 53 upwardly to withdraw the punch, whereupon spring 56 is effective to lift the upper die member 22 slightly to enable the substrate S to be withdrawn. Another substrate S feeds between the dies as member 22 continues its upward stroke, rotating the pinion 34 in the opposite sense without any effect on the wheel 32 since, in the clockwise sense the pinion may rotate freely by reason of the unidirectional clutch 35. During the next closing stroke of the die, the strip 3 is again advanced as illustrated in FIGS. 6D and 7D.

We claim: 1. A device for applying patches of a strip of resilient thermally adhesive material to a substrate, comprising:

a pair of relatively displaceable die members receiving said substrate between them, at least one of said die members being continuously heated; means for feeding said strip into juxtaposition with a surface of said substrate between said die members', cutting means on said die members for severing a portion of the strip juxtaposed with said substrate from the remainder of said strip; means for buckling said strip as it is fed into juxtaposition with said surface of said substrate for preventing adhesion of said remainder of said strip to said cutting means and of said severed portion to said die members during the cutting of said severed portion from said remainder of said strip; means on said die members for compressing said severed portion against said substrate and thereby bonding said severed portion thereto; and a holddown element on one of said members effective intermediate the severing of said portion of the bonding thereof to said substrate for yieldably retaining said portion against said substrate. 2. A device for applying patches of a strip of resilient thermally adhesive material to a substrate, comprising:

a pair of relatively displaceable die members receiving said substrate between them, at least one of said die members being continuously heated; means for feeding said strip into juxtaposition with a surface of said substrate between said die member; cutting means on said die members for severing a portion of the strip juxtaposed with said substrate from the remainder of said strip; means on said die members for compressing said severed portion against said substrate and thereby bonding said severed portion thereto; and

a hold-down element on one of said members and effective intermediate the severing of said portion and the bonding thereof to said substrate for yieldably retaining said portion against said substrate, said means for feeding said strip into juxtaposition with a surface of said substrate including means for imparting a transverse curvature to said strip for stiffening same during such feeding.

3. The device defined in claim 2 wherein said cutting means includes a pair of cutting edges spaced apart in the direction of feed of said strip for forming a trailing edge of said portion simultaneously with a leading edge of the remainder of said strip and corresponding to a leading edge of the next strip portion to be applied to a substrate.

4. The device defined in claim 3 wherein the means for imparting transverse curvature to said strip includes a channel formed on one of said members and having a width less than the undeflected width of said strip.

5. The device defined in claim 4 wherein said feed wheel is formed with a resilient periphery of substantially circular cross-section for engagement with said strip.

6. The device defined in claim 5, further comprising a pinion, unidirectional clutch means operatively connecting said pinion to said wheel and a rack on the other of said members engageable with said pinion for rotating same upon relative displacement of said members.

7. The device defined in claim 2 wherein one of said members is provided with a punch displaceable to pierce said portion and said substrate.

8. The device defined in claim 2 wherein said cutting means includes a cutting edge transverse to the direction of feed of said strip for severing said portion from said strip substantially flush with an edge of said sub strate.

9. The device defined in claim 8 wherein said cutting means includes a further cutting edge of arcuate configuration forming a convex extremity at a leading end of said strip.

10. The device defined in claim 9 wherein said cutting edges are provided on a blade member curved in a plane transverse to the direction of feed of said strip. 

1. A DEVICE FOR APPLYING PATCHES OF A STRIP OF RESILIENT THERMALLY ADHESIVE MATERIAL TO A SUBSTRATE, COMPRISING: A PAIR OF RELATIVELY DISPLACEABLE DIE MEMBERS RECEIVING SAID SUBSTRATE BETWEEN THEM, AT LEAST ONE OF SAIDDIE MEMBERS BEING CONTINUOUSLY HEATED; MEANS FOR FEEDING SAID STRIP INTO JUXTAPOSITION WITH A SURFACE OF SAID SUBSTRATE BETWEEN SAID DIE MEMBERS; CUTTING MEANS ON SAID DIE MEMBERS FOR SEVERING A PORTION OF THE STRIP JUXTAPOSED WITH SAID SUBSTRATE FROM THE REMAINDER OF SAID STRIP; MEANS FOR BUCKLING SAID STRIP AS IT IS FED INTO JUXTAPOSITION WITH SAID SURFACE OF SAID SUBSTRATE FOR PREVENTING ADHESION OF SAID REMAINDER OF SAID STRIP TO SAID CUTTING MEANS AND OF SAID SEVERED PORTION TO SAID DIE MEMBERS DURING AT CUTTING OF SAID SEVERED PORTION FROM SAID REMAINDER OF SAID STRIP; MEANS ON SAID DIE MEMBERS FOR COMPRESSING SAID SEVERED PORTIONS AGAINST SAID SUBSTRATE AND THEREBY BONDING SAID SEVERED PORTION THERETO; AND A HOLDDOWN ELEMENT ON ONE OF SAID MEMBERS EFFECTIVE INTERMEDIATE THE SEVERING OF SAID PORTION OF THE BONDING THEREOF TO SAID SUBSTRATE FOR YIELDABLY RETAINING SAID PORTION AGAINST SAID SUBSTRATE.
 2. A device for applying patches of a strip of resilient thermally adhesive material to a substrate, comprising: a pair of relatively displaceable die members receiving said substrate between them, at least one of said die members being continuously heated; means for feeding said strip into juxtaposition with a surface of said substrate between said die member; cutting means on said die members for severing a portion of the strip juxtaposed with said substrate from the remainder of said strip; means on said die members for compressing said severed portion against said substrate and thereby bonding said severed portion thereto; and a hold-down element on one of said members and effective intermediate the severing of said portion and the bonding thereof to said substrate for yieldably retaining said portion against said substrate, said means for feeding said strip into juxtaposition with a surface of said substrate including means for imparting a transverse curvature to said strip for stiffening same during such feeding.
 3. The device defined in claim 2 wherein said cutting means includes a pair of cutting edges spaced apart in the direction of feed of said strip for forming a trailing edge of said portion simultaneously with a leading edge of the remainder of said strip and corresponding to a leading edge of the next strip portion to be applied to a substrate.
 4. The device defined in claim 3 wherein the means for imparting transverse curvature to said strip includes a channel formed on one of said members and having a width less than the undeflected width of said strip.
 5. The device defined in claim 4 wherein said feed wheel is formed with a resilient periphery of substantially circular cross-section for engagement with said strip.
 6. The device defined in claim 5, further comprising a pinion, unidirectional clutch means operatively connecting said pinion to said wheel and a rack on the other of said members engageable with said pinion for rotating same upon relative displacement of said members.
 7. The device defined in claim 2 wherein one of said members is provided with a punch displaceable to pierce said portion and said substrate.
 8. The device defined in claim 2 wherein said cutting means includes a cutting edge transverse to the direction of feed of said strip for severing said portion from said strip substantially flush with an edge of said substrate.
 9. The device defined in claim 8 wherein said cutting means includes a further cutting edge of arcuate configuration forming a convex extremity at a leading end of said strip.
 10. The device defined in claim 9 wherein said cutting edges are provided on a blade member curved in a plane transverse to the direction of feed of said strip. 